Sanitary tissue product roll

ABSTRACT

Sanitary tissue products, especially sanitary tissue products in the form of rolls of sanitary tissue products wherein the sanitary tissue product rolls exhibit a width of less than about 11.43 cm (4.5 inches) are provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/921,819 filed Apr. 4, 2007.

FIELD OF THE INVENTION

The present invention relates to the field of sanitary tissue products, especially sanitary tissue products in the form of rolls of sanitary tissue products.

BACKGROUND OF THE INVENTION

Producers and marketers of sanitary tissue products are constantly striving to help consumers choose a sanitary tissue product that meets their needs. One of the persistent needs of consumers is long roll life, which correlates to the length of the sanitary tissue product on the roll. Product improvements to sanitary tissue products over time have been directed to making sanitary tissue products stronger, softer, and/or more absorbent. Consequently, the length of sanitary tissue products available on a single roll has been reduced. This is due to the fact that such product improvements have generally required greater and greater thickness of individual sheets. Roll sizes have thus been limited due to the fact that rolls are best mounted in suspension by means, such as residential wall-mounted toilet paper holders, so that they may be rotated about the roll's core to dispense sheets of the product for use. It has been a typical practice in the sanitary tissue product industry to offer roll diameters of less than about 14 cm (5.5 inches) and/or less than about 12.7 cm (5 inches) because above a roll diameter of about 12.7 cm (5 inches), many classical suspension means, especially residential wall-mounted toilet paper holders, require auxiliary suspension aids to facilitate unencumbered rotation of the roll about its core and, above a roll diameter of about 14 cm (5.5 inches), another segment, such as business establishments that contain “public” restrooms, requires auxiliary aids different from the classical suspension means found in residential bathrooms.

As the length of products has been reduced over the years, several “extended roll life” products have emerged; these traditionally have been designated by a number of names. Examples include “Double Roll”, “Big Roll”, “Jumbo Roll”, “Triple Roll”, “Supersize” or just a very large number of sheets for example “1000”, as in “Scott 1000®”. Such names have become ubiquitous and confusing to the consumer and, while the roll sizes have varied widely, there is no expectation that any of these products will have enough extended roll life (as represented by the roll diameter) to suggest the need for an auxiliary suspension aid. More recently, the subnomen “Mega Roll” has come into use and is clearly directed at a special segment of extended roll life products; those that are above the threshold requiring auxiliary suspension aids, i.e. at about 12.7 cm (5 inches) or greater roll diameter and/or about 14 cm (5.5 inches) or greater roll diameter.

Consumers whom are seeking “Mega Roll” products are often willing to endure particular problems associated with their difficulty in mounting the Mega Roll products on a residential wall-mounted toilet paper holder; e.g. they are often willing to deploy an auxiliary suspension means. Because of their special status as extended roll life seekers, they may be referred to as extended roll life extremists.

Accordingly, there exists a problem that needs to be solved. The problem is providing, in an efficient manner, consumers that are seeking “Mega Roll” sanitary tissue products (“extended roll life extremists”) extended roll life over conventional rolled sanitary tissue products, especially over conventional rolled residential sanitary tissue products.

SUMMARY OF THE INVENTION

It has been surprisingly found that it is possible to satisfy the needs of these extremists for extended roll life in a more cost effective format by using a novel combination of roll diameter, roll width, and subnomen. The solution to the problem of providing “Mega Roll” sanitary tissue products is a sanitary tissue product that exhibits a sanitary tissue product roll width of less than about 11.43 cm (4.5 inches).

In one example of the present invention, a sanitary tissue product roll having a width of less than about 4.5 inches and an external diameter of greater than about 5.5 inches, is provided.

In another example of the present invention, a package comprising one or more sanitary tissue product rolls according to the present invention wherein the package comprises a textual size indicator, is provided.

In still another example of the present invention, a package comprising a sanitary tissue product roll exhibiting a width of less than about 4.5 inches wherein the package comprises a textual size indicator comprising the text Mega, is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a sanitary tissue product roll according to the present invention;

FIG. 2 is a schematic representation of a sanitary tissue product roll package according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION Definitions

“Fiber” as used herein means an elongate particulate having an apparent length greatly exceeding its apparent width, i.e. a length to diameter ratio of at least about 10. Fibers have some integrity, i.e. manifested by some intrinsic strength. If an apparent elongate particulate, supported by a substrate, fails to have enough instrinsic strength to support itself, it is not a fiber, but may be a faux fiber. More specifically, as used herein, “fiber” refers to papermaking fibers. The present invention contemplates the use of a variety of papermaking fibers, such as, for example, natural fibers or synthetic fibers, or any other suitable fibers, and any combination thereof. Papermaking fibers useful in the present invention include cellulosic fibers commonly known as wood pulp fibers. Applicable wood pulps include chemical pulps, such as Kraft, sulfite, and sulfate pulps, as well as mechanical pulps including, for example, groundwood, thermomechanical pulp and chemically modified thermomechanical pulp. Chemical pulps, however, may be preferred since they impart a superior tactile sense of softness to tissue sheets made therefrom. Pulps derived from both deciduous trees (hereinafter, also referred to as “hardwood”) and coniferous trees (hereinafter, also referred to as “softwood”) may be utilized. The hardwood and softwood fibers can be blended, or alternatively, can be deposited in layers to provide a stratified web. U.S. Pat. No. 4,300,981 and U.S. Pat. No. 3,994,771 are incorporated herein by reference for the purpose of disclosing layering of hardwood and softwood fibers. Also applicable to the present invention are fibers derived from recycled paper, which may contain any or all of the above categories as well as other non-fibrous materials such as fillers and adhesives used to facilitate the original papermaking.

In addition to the various wood pulp fibers, other cellulosic fibers such as cotton linters, rayon, and bagasse can be used in this invention. Synthetic fibers and/or non-naturally occurring fibers, such as polymeric fibers including natural polymeric fibers such as starch and/or modified starch polymeric fibers, can also be used. Elastomeric polymers, polypropylene, polyethylene, polyester, polyolefin, and nylon, can be used. The polymeric fibers can be produced by spunbond processes, meltblown processes, and other suitable methods known in the art.

An embryonic fibrous web can be typically prepared from an aqueous dispersion of papermaking fibers, though dispersions in liquids other than water can be used. The fibers are dispersed in the carrier liquid to have a consistency of from about 0.1 to about 0.3 percent. It is believed that the present invention can also be applicable to moist forming operations where the fibers are dispersed in a carrier liquid to have a consistency of less than about 50% and/or less than about 10%.

“Fibrous structure” as used herein means a structure that comprises one or more fibers. In one example, a fibrous structure according to the present invention means an orderly arrangement of fibers within a structure in order to perform a function. Nonlimiting examples of fibrous structures of the present invention include composite materials (including reinforced plastics and reinforced cement), paper, fabrics (including woven, knitted, and non-woven), and absorbent pads (for example for diapers or feminine hygiene products). A bag of loose fibers is not a fibrous structure in accordance with the present invention.

Nonlimiting examples of processes for making fibrous structures include known wet-laid papermaking processes and air-laid papermaking processes. Such processes typically include steps of preparing a fiber composition in the form of a suspension in a medium, either wet, more specifically aqueous medium, or dry, more specifically gaseous, i.e. with air as medium. The aqueous medium used for wet-laid processes is oftentimes referred to as a fiber slurry. The fibrous suspension is then used to deposit a plurality of fibers onto a forming wire or belt such that an embryonic fibrous structure is formed, after which drying and/or bonding the fibers together results in a fibrous structure. Further processing the fibrous structure may be carried out such that a finished fibrous structure is formed. For example, in typical papermaking processes, the finished fibrous structure is the fibrous structure that is wound on the reel at the end of papermaking, and may subsequently be converted into a finished product, e.g. a sanitary tissue product.

The fibrous structures of the present invention may be homogeneous or may be layered. If layered, the fibrous structures may comprise at least two and/or at least three and/or at least four and/or at least five layers.

The fibrous structures of the present invention may be co-formed fibrous structures.

“Sanitary tissue product” as used herein means a soft, low density (i.e. < about 0.15 g/cm³) web useful as a wiping implement for post-urinary and post-bowel movement cleaning (toilet tissue), for otorhinolaryngological discharges (facial tissue), and multi-functional absorbent and cleaning uses (absorbent towels). The sanitary tissue product may be convolutedly wound upon itself about a core or without a core to form a sanitary tissue product roll.

In one example, the sanitary tissue product of the present invention comprises a fibrous structure according to the present invention.

In one example, the sanitary tissue product of the present invention is a 2-ply sanitary tissue product comprising two fibrous structures according to the present invention.

The sanitary tissue products of the present invention may exhibit a basis weight between about 10 g/m² to about 120 g/m² and/or from about 15 g/m² to about 110 g/m² and/or from about 20 g/m² to about 100 g/m² and/or from about 30 to 90 g/m². In addition, the sanitary tissue product of the present invention may exhibit a basis weight between about 40 g/m² to about 120 g/m² and/or from about 50 g/m² to about 110 g/m² and/or from about 55 g/m² to about 105 g/m² and/or from about 60 to 100 g/m².

The sanitary tissue products of the present invention may exhibit a total dry tensile strength of greater than about 59 g/cm (150 g/in) and/or from about 78 g/cm (200 g/in) to about 394 g/cm (1000 g/in) and/or from about 98 g/cm (250 g/in) to about 335 g/cm (850 g/in). In addition, the sanitary tissue product of the present invention may exhibit a total dry tensile strength of greater than about 196 g/cm (500 g/in) and/or from about 196 g/cm (500 g/in) to about 394 g/cm (1000 g/in) and/or from about 216 g/cm (550 g/in) to about 335 g/cm (850 g/in) and/or from about 236 g/cm (600 g/in) to about 315 g/cm (800 g/in). In one example, the sanitary tissue product exhibits a total dry tensile strength of less than about 394 g/cm (1000 g/in) and/or less than about 335 g/cm (850 g/in).

In another example, the sanitary tissue products of the present invention may exhibit a total dry tensile strength of greater than about 315 g/cm (800 g/in) and/or greater than about 354 g/cm (900 g/in) and/or greater than about 394 g/cm (1000 g/in) and/or from about 315 g/cm (800 g/in) to about 1968 g/cm (5000 g/in) and/or from about 354 g/cm (900 g/in) to about 1181 g/cm (3000 g/in) and/or from about 354 g/cm (900 g/in) to about 984 g/cm (2500 g/in) and/or from about 394 g/cm (1000 g/in) to about 787 g/cm (2000 g/in).

The sanitary tissue products of the present invention may exhibit a total wet tensile strength of less than about 78 g/cm (200 g/in) and/or less than about 59 g/cm (150 g/in) and/or less than about 39 g/cm (100 g/in) and/or less than about 29 g/cm (75 g/in).

The sanitary tissue products of the present invention may exhibit a density of less than about 0.60 g/cm³ and/or less than about 0.30 g/cm³ and/or less than about 0.20 g/cm³ and/or less than about 0.10 g/cm³ and/or less than about 0.07 g/cm³ and/or less than about 0.05 g/cm³ and/or from about 0.01 g/cm³ to about 0.20 g/cm³ and/or from about 0.02 g/cm³ to about 0.10 g/cm³.

The sanitary tissue product rolls of the present invention may comprise a plurality of connected, but perforated sheets, that are separably dispensable from adjacent sheets.

The sanitary tissue products of the present invention may comprises additives such as softening agents, temporary wet strength agents, permanent wet strength agents, bulk softening agents, lotions, silicones, and other types of additives suitable for inclusion in and/or on sanitary tissue products.

“Weight average molecular weight” as used herein means the weight average molecular weight as determined using gel permeation chromatography according to the protocol found in Colloids and Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

“Basis Weight” as used herein is the weight per unit area of a sample reported in lbs/3000 ft² or g/m². Basis weight is measured by preparing one or more samples of a certain area (m²) and weighing the sample(s) of a fibrous structure according to the present invention and/or a paper product comprising such fibrous structure on a top loading balance with a minimum resolution of 0.01 g. The balance is protected from air drafts and other disturbances using a draft shield. Weights are recorded when the readings on the balance become constant. The average weight (g) is calculated and the average area of the samples (m²). The basis weight (g/m²) is calculated by dividing the average weight (g) by the average area of the samples (m²).

“Machine Direction” or “MD” as used herein means the direction parallel to the flow of the fibrous structure through the papermaking machine and/or product manufacturing equipment.

“Cross Machine Direction” or “CD” as used herein means the direction perpendicular to the machine direction in the same plane of the fibrous structure and/or paper product comprising the fibrous structure.

“Ply” or “Plies” as used herein means an individual fibrous structure optionally to be disposed in a substantially contiguous, face-to-face relationship with other plies, forming a multiple ply fibrous structure. It is also contemplated that a single fibrous structure can effectively form two “plies” or multiple “plies”, for example, by being folded on itself.

As used herein, the articles “a” and “an” when used herein, for example, “an anionic surfactant” or “a fiber” is understood to mean one or more of the material that is claimed or described.

All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.

Unless otherwise noted, all component or composition levels are in reference to the active level of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources.

Sanitary Tissue Product Roll

As shown in FIG. 1, a sanitary tissue product roll 10 of the present invention exhibits a width W of less than about 11.43 cm (4.5 inches) and/or less than about 10.92 cm (4.3 inches). In one example, the sanitary tissue product roll 10 of the present invention exhibits a width W of greater than about 8.89 cm (3.5 inches). By having widths W of less than about 11.43 cm (4.5 inches), wood pulp and thus trees can be conserved. In addition, the widths W of less than about 11.43 cm (4.5 inches) helps reduce unnecessary waste of sanitary tissue products. Further yet, by having the sanitary tissue product rolls 10 exhibits widths W of less than about 11.43 cm (4.5 inches) the length of the fibrous structure 12 on the roll can be increased thus, extending the roll life of the sanitary tissue product roll 10.

The sanitary tissue product roll 10 of the present invention comprises a fibrous structure 12. The fibrous structure 12 may be convolutedly wound upon itself about a core 14 or without the presence of a core.

The sanitary tissue product roll 10 of the present invention may exhibit an external diameter D_(E) of greater than about 13.97 cm (5.5 inches) and/or greater than about 14.48 cm (5.7 inches) and/or greater than or equal to about 15.24 cm (6 inches) and/or greater than about 16 cm (6.3 inches). In one example, the sanitary tissue product roll 10 of the present invention exhibits an external diameter D_(E) of less than about 17.78 cm (7 inches) and/or less than about 17.27 cm (6.8 inches) and/or less than about 16.51 cm (6.5 inches).

The sanitary tissue product roll 10 of the present invention may exhibit an internal diameter D_(I) of greater than about 2.54 cm (1 inch) and/or greater than about 3.17 cm (1.25 inches) and/or greater than about 3.81 cm (1.5 inches). In one example, the sanitary tissue product roll 10 of the present invention exhibits an internal diameter D_(I) of less than about 12.7 cm (5 inches) and/or less than about 10.92 cm (4.3 inches) and/or less than about 8.89 cm (3.5 inches) and/or less than about 6.98 cm (2.75 inches).

The present invention solves the problem facing consumers that are seeking “Mega Roll” sanitary tissue products by reducing the width W of conventional sanitary tissue product rolls such as to less than about 11.43 cm (4.5 inches). Further, it has been found that by adjusting the external diameter D_(E) and internal diameter D_(I), the life of a sanitary tissue product roll can be influenced to provide extended roll life sanitary tissue product rolls.

The sanitary tissue product roll 10 of the present invention may comprise a fibrous structure 12 that comprises a pattern, such as an emboss pattern, a through-air-dried pattern, especially a repeating, non-random through-air-dried pattern, print, tufts (which are generated by any known tuft generating process), two or more regions of different densities.

Process for Making Sanitary Tissue Product Roll

The sanitary tissue product roll of the present invention may be made by any suitable process. For example, a fibrous structure prepared by a through-air-dried papermaking process may be rolled into a log as is known in the art. The log may then be cut by a logsaw to produce a sanitary tissue product roll having a width of less than about 11.43 cm (4.5 inches). Further, the length of fibrous structure present on the sanitary tissue product roll may be controlled by suitable known means such that the resulting sanitary tissue product roll exhibits an external diameter of greater than about 13.97 cm (5.5 inches).

Sanitary Tissue Product Roll Package

As shown in FIG. 2, to aid in communicating to a consumer seeking a “Mega Roll” of sanitary tissue product (i.e., a sanitary tissue product roll that exhibits extended roll life compared to currently marketed sanitary tissue product rolls), one or more sanitary tissue product rolls (not shown), especially one or more sanitary tissue product rolls according to the present invention, may be housed within a package 16 comprising a textual size indicator 18. The textual size indicator 18 may comprise any style of font for the text. Further, the textual size indicator may be present on any surface of the package 16. In one example, the textual size indicator 18 is present on a surface of the package 16 that also comprises a brand name, such as Charmin®. In one example, the textual size indicator 18 present on the package 16 comprises the text “Mega” and/or “MEGA” and/or “Mega Roll” and/or “MEGA ROLL” and/or “Mega Sized” and/or “MEGA SIZED” and/or “Super Mega” and/or “Super Mega Roll” and/or “SUPER MEGA” and/or “SUPER MEGA ROLL” and/or “Super Mega Sized” and/or “SUPER MEGA SIZED” and/or “Grand Roll” and/or “GRAND ROLL” and/or “Colossal Roll” and/or “COLOSSAL ROLL” and/or synonyms of any of the above size indicators. The size indicators may be in English or some equivalent translation for another language such as French, Spanish, and the like. The package 16 may be made from any suitable packaging material 20 known in the art. Nonlimiting examples include polywrap, polymer films, such as polyolefin films, polyester films, paper, cardboard, plastic, wood, metal and other suitable packaging materials. In one example, the package 16 comprises a polyolefin film. In another example, the package 16 comprises a polyester film. In still another example, the package 16 comprises cardboard.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

1. A sanitary tissue product roll having a width of less than about 4.5″ and an external diameter of greater than about 5.5″.
 2. The roll according to claim 1 wherein the roll has a width of less than about 4.3″.
 3. The roll according to claim 1 wherein the roll has a width of greater than about 3.5″.
 4. The roll according to claim 1 wherein the roll has an external diameter of less than about 7″.
 5. The roll according to claim 1 wherein the roll has an internal diameter of greater than about 1″.
 6. The roll according to claim 1 wherein the roll has an internal diameter of less than about 5″.
 7. The roll according to claim 1 wherein the roll comprises a core.
 8. The roll according to claim 1 wherein the roll is coreless.
 9. The roll according to claim 1 wherein the roll comprises a fibrous structure that is convolutedly wound.
 10. The roll according to claim 9 wherein the fibrous structure comprises a plurality of sheets that are separably dispensable from adjacent sheets.
 11. The roll according to claim 9 wherein the fibrous structure comprises a pattern.
 12. The roll according to claim 11 wherein the fibrous structure comprises an emboss pattern.
 13. The roll according to claim 9 wherein the fibrous structure comprises a through-air-dried fibrous structure.
 14. The roll according to claim 13 wherein the fibrous structure comprises regions that exhibit different densities.
 15. The roll according to claim 9 wherein the fibrous structure comprises a conventionally pressed fibrous structure.
 16. The roll according to claim 9 wherein the fibrous structure comprises an uncreped fibrous structure.
 17. The roll according to claim 1 wherein the roll is a toilet paper roll.
 18. The roll according to claim 1 wherein the sanitary tissue product consists of two plies of the fibrous structure.
 19. A package comprising one or more rolls according to claim 1 wherein the package comprises a textual size indicator comprising the text Mega.
 20. A package comprising a sanitary tissue product exhibiting a width of less than about 4.5″ wherein the package comprises a textual size indicator comprising the text Mega. 